Craftsman 934205111, 20511 Owner’s Manual

6E/ARS

CRRFTSMRK

Operator's Guide

WIRE FEED

MIG WELDER

Model No.

934.20511 1

. WARRANTY
o INTRODUCTION

• SAFETY SUMMARY

o SPECIFICATIONS
o INSTALLATION

o OPERATION
° MAINTENANCE
o SCHEMATIC

• WIRING DIAGRAM

° REPLACEMENT PARTS

• ESPANOL

CAUTION: Read and follow
all Safety Rules and

Operating Instructions before

First Use of this Product.

Sears, Roebuck and Co., Hoffman Estates, IL 60179 USA

811-635-000 Rev, A (,January 2001)

On Welding Gun or Cables, Welder, and Welder's Transformer

Full One Year Warranty for Craftsman
Welding Gun or Cables. For one year

from the date of purchase, when the
welding gun or cables are operated and

maintained according to the owner's
manual instructions, if the welding gun
or cables fail due to a defect in material

or workmanship, Sears will repair or

replace the welding gun or cables free of
charge. This warranty does not cover

parts consumed in normal operation,
such as contact tips, nozzles, gun liners,
and drive rollers

Full Three.._ear Warranty on Craftsman

Welder For three years from the date of

purchase, when the welder is operated

and maintained according to the owner's

manual instructions, if the welder fails
due to a defect in material or

workmanship, Sears will repair or
replace the welder free of charge. This

warranty does not cover the welding
gun, cables, or normal consumable

parts._

WARRANTY SERVICE IS AVAILABLE

BY SIMPLY CONTACTING THE
NEAREST SEARS SERVICE CENTER.

This warranty applies only while this

product is in use in the United States°

This warranty gives you specific legal

rights, and you may also have other
rights which vary from state to state.

Sears Roebuck and Co., Dept. 817WA,
Hoffman Estates, IL 60179.

2

CRAFTSMAN FULL WARRANTY ......................................................... 2

TABLE OF CONTENTS ......................................................................... 3

INTRODUCTION .................................................................................... 4

SAFETY SUMMARY ............................................................................... 5

SAFETY INFORMATION ......................................................................... 5

SHOCK HAZARDS ............................................................................... 6

FIRE HAZARDS .............................................................................................. 6

FLASH HAZARDS ............................................................................................6

FUME HAZARDS .......................................................................................................6

COMPRESSED GASSES AND EQU1PMENT HAZARDS .................. 6

BURN HAZARDS ..............................................................................................7

ADDITIONAL SAFETY INFORMATION ................................................... 7

WELDER SPECIFICATIONS .................................................................. 8

DESCRIPTION .................................................................................................... 8

WELDER OPERATING CHARACTERISTICS .................................................8

DUTY CYCLE ..................................................................................... 8

INTERNAL THERMAL PROTECTION .................................................. 8

WELDER INSTALLATION ..................................................................... 9

POWER SOURCE CONNECTION .......................................................... 9

POWER REQUIREMENTS ........................................................................... 9

CONNECT TO POWER SOURCE .............................................................. 9

EXTENSION CORDS ................................................................................. 9

ASSEMBLING THE WELDER ............................................................................9

UNPACKING THE WELDER ..................................................................... 9

INSTALL THE GROUND CLAMP ......................................................................9

INSTALL THE TANK TRAY AND BRACKET ............................................. 9

INSTALL THE SHIELDING GAS .............................................................. 10

CHECK THE GAS FLOW ........................................................................................11

ALIGN AND SET THE DRIVE ROLLER ............................................. 1t

STANDARD DRIVE ROLLER ..................................................................... 11

NEOPRENE DRIVE ROLLER ..................................................................... 12

INSTALL THE WELDING WIRE ......................................................................13

SET THE WIRE DRIVE TENSION ............................................................ 15

CHANGE POLARITY .................................................................................... t 5

OPERATION ......................................................................................... 16

CONTROLS AND INDICATORS .............................................................. 16

MAINTENANCE .................................................................................... 17

GENERAL ............................................................................................................ 17

REPLACE A GUN LINER .......................................................................... 17

MAINTAINING THE CONTACT TIP ...................................................... 19

MAINTAINING THE NOZZLE ..................................................................... t9

TESTING FOR A SHORTED NOZZLE ............................................ 20

PREVENTIVE MAINTENANCE ......................................................... 20

TROUBLESHOOTING ......................................................................... 20

SCHEMATIC ......................................................................................... 22

WIRING DIAGRAM ............................................................................... 23

REPLACEMENT PARTS LIST ............................................................. 24

3

This Welder User's Guide provides
specific information about your wire feed

welder° It is to be used together with the
Welding Instruction Guide to provide all

of the information needed to safely and

effectively use your wire feed welder.

The information in this book applies to

your specific model of wire feed welder
and gives instruction on set-up,
installation, and actual use of the
welder.

Where information is shown that does
not necessarily apply to all models or

brands of welder, it will be marked as

either optional on some welder models

or does not apply to all models,

4

Every craftsman respects the tools with
which they work. They know that the

tools represent years of constantly

improved designs and developments.

The true craftsman also knows that tools
are dangerous if misused or abused.

Reading this Operator's Guide and the
Welding Instruction Guide before using
the welder will enable you to do a better,

safer job. Learn the welder's

applications and limitations as well as
the specific potential hazards peculiar to

welding

SAFETY INFORMATION

The following safety information is

provided as guidelines to help you

operate your new welder under the

safest possible conditions Any

equipment that uses electrical power

can be potentially dangerous to use

when safety or safe handling instructions

are not known or not followed. The

following safety information is provided

to give you the information necessary for

safe use and operation°

When a procedure step is preceded by

a WARNING, it is an indication that the

step contains a procedure that might be

injurious to a person if proper safety
precautions are not heeded,

When a procedure step is preceded by

a CAUTION, it is an indication that the
step contains a procedure that might

damage the equipment being used.
A NOTE may be used before or after a

procedure step to highlight or explain
something in that step,

READ ALL SAFETY INSTRUCTIONS

CAREFULLY before attempting to

install, operate, or service this welder.
Failure to comply with these instructions

could result In personal injury and/or
property damage.

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE.

Note: The following safety alert

symbols identify important

safety messages in this
manual,.

When you see one of the symbols
shown here, be alert to the possibility of

personal injury and carefully read the
message that follows.

This symbol indicates that the

possibility of electric shock
hazard exists during the

operation of the step(s) that
follow.

This symbol indicates that the
possibility of fire hazard exists
during the operation of the

step(s) that follow.

This symbol indicates that the

helmet must be worn during

the step(s) that follow to

protect against eye damage
and bums due to flash

hazard,

This symbol indicates that the

possibility of toxic gas hazard
exists during operation of the

step(s) that follow.

This symbol indicates that the

possibility of being burned by
hot slag exists during

operation of the step(s) that
follow.

This symbol indicates that the
eye protection should be worn

to protect against flying debris

in the following step(s)

This symbol indicates that the

possibility of injury or death
exists due to improper
handling and maintenance of

compressed gas cylinders or
regulators

Full explanations of the specific hazards
are shown in the WELDING

INSTRUCTION GUIDE. Make sure you

have read and understand all of the

5

information before proceeding with any
of the instructions contained in this

user's guide_

Published standards on safety are
available. They are listed in

ADDITIONAL SAFETY INFORMATION

at the end of this SAFETY SUMMARY,,

The National Electrical Code,

Occupational Safety and Health Act

regulations, local industrial codes and

local inspection requirements also

provide a basis for equipment

installation, use, and service

SHOCK HAZARDS

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYES
AND BURN SKIN! To reduce risk of

injury from arc rays, read,

understand, and follow the following
safety instructions° In addition, make

certain that anyone else that uses
this welding equipment, or is a

bystander in the welding area,
understands and follows these safety

instructions as well,

WARNING

ELECTRIC SHOCK CAN KILL! To

reduce the risk of death or serious
injury from shock, read, understand,

and follow the following safety
instructions, tn addition, make

certain that anyone else who uses
this welding equipment, or who is a
bystander in the welding area

understands and follows these safety

instructions as welt,

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSE
DEATH, INJURY, AND PROPERTY

DAMAGE! To reduce risk of death,
injury, or property damage from fire

or explosion, read, understand, and
follow the following safety

instruction& tn addition, make
certain that anyone else that uses
this welding equipment, or is a

bystander in the welding area,

understands and follows these safety

instructions as well. REMEMBER!

Welding by nature produces sparks,

hot spatter, molten metal drops, hot

slag, and hot metal parts that can

start fires, burn skin, and damage

eyes,

6

FUME HAZARDS

WARNING

FUMES, GASSES, AND VAPORS
CAN CAUSE DISCOMFORT,

ILLNESS, AND DEATH! To reduce
risk of discomfort, illness, or death,

read, understand, and follow the
following safety instructions. In

addition, make certain that anyone
else that uses this welding equipment
or is a bystander in the welding area,

understands and follows these safety
instructions as well

COMPRESSED GASSES AND
EQUIPMENT HAZARDS

WARNING

IMPROPER HANDLING AND
MAINTENANCE OF COMPRESSED

GAS CYLINDERS AND
REGULATORS CAN RESULT IN

SERIOUS INJURY OR DEATH! To

reduce risk of injury or death from

compressed gasses and equipment
hazards, read understand and follow

the following safety instructions, In
addition, make certain that anyone

else who uses this welding

equipmentor a bystanderin the
weldingarea understandsand
followsthesesafetyinstructionsas
well.

Do notuseflammablegasseswith

MIGwelders. Only inertor

nonflammablegassesare suitablefor

MIGwelding. Examplesare Carbon

Dioxide,Argon,Helium,etc. or

mixturesof morethanone of these

gasseso

BURN HAZARDS

WARNING

Hot slag can cause fires and

serious injury from burns. To

reduce the risk of discomfort or
serious injury due to burns always

wear heavy protective clothing, eye

and face protection, and gloves

designed for welding. To prevent the

risk of fires starting, use a metal plate
or some other material with a high

flash point to catch and shield
combustibles from the hot slag

ADDITIONAL SAFETY

INFORMATION

For additional information concerning

welding safety, refer to the following
standards and comply with them as

applicable.

o ANSl Standard Z49.1 -- SAFETY IN

WELDING AND CUTTING --

obtainable from the American Welding
Society, 550 NW Le Jeune Road,

Miami, FL 33126 Telephone (800)
443-9353, Fax [phone]

www,amweldoorg or www aws.org

° ANSI Standard Z87.1 -- SAFE

PRACTICE FOR OCCUPATION AND

EDUCATIONAL EYE AND FACE
PROTECTION -- obtainable from the

American National Standards Institute,

11 West 42_ Sto, New York, NY
t0036 Telephone [phone],

Fax [phone] --- www.ansi.org

o NFPA Standard 51B --- CUTTING

AND WELDING PROCESS --
obtainable from the National Fire

Protection Association, t
Batterymarch Park, P.O. Box 9t01,

Quincy, MA 02269-9101 Telephone
[phone], Fax [phone]

.--- www.nfpa..org

* CGA Pamphlet Pq -- SAFE

HANDLING OF COMPRESSED

GASSES IN CYLINDERS --
obtainable from the Compressed Gas

Association, 1725 Jefferson Davis

Highway, Suite 1004, Arlington, VA

22202-4102 Telephone (703) 412-

0900 Fax [phone]-
www cagneLcom

. OSHA Standard 29 CFR, Part 1910,

Subpart Q., WELDING, CUTTING
AND BRAZING --- obtainable from

your state OSHA office or U. S. Dept.
of Labor OSHA, Office of Public
Affairs, Room N3647, 200 Constitution

Ave Washington, DC 20210--
wwwoshagov

. CSA Standard W1172 -- Code for

SAFETY IN WELDING AND
CUTTING° w obtainable from

Canadian Standards Association, 178
Rexdale Btvd. Etobicoke, Ontario

M9W 1R3 -- wwwcs&ca

o American Welding Society Standard

A60. WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD

COMBUSTIBLES. -- obtainable from
the American Welding Society, 550

NW Le Jeune Road, Miami, FL 33126

Telephone [phone], Fax (305)
443-7559 -- wwwoamweldorg or

www. awsoorg

DESCRIPTION

Your new wire feed welder is designed
for maintenance and sheet metal
fabrication. The welder consists of a

single-phase power transformer,

stabilizer, rectifier, and a unique built-in

control/feeder_

Now you can weld sheet metal from 26

gauge up to 3/16 inch thick with a single

pass,. You can weld thicker steel with

beveling and multiple pass techniques..
Table 1 lists your MIG welder

specifications.

Table 1. Welder Specifications

Primary (input) volts 120 Vac
Primary (inputs) Amps 20

Phase Single

Frequency 60 Hz
Secondary (output) volts 18_5
Secondary (UL output) amps 90
Open Circuit Volts (Max.) 28 Vdc

Duty Cycle Rating 20%

MIG welders equipped with gas are

capable of welding with 0_024 (0.6mm)
and 0.030 (0.Smm) solid steel wire on dc

reverse polarity and with 0_030 (0.Smm)

self-shielding flux-core wire on dc
straight polarity. Larger, 0.035 inch

(0.gmm) diameter solid steel wire, on dc
reverse polarity may also be used on
this welder. The use of larger diameter

wire makes welding difficult and the

results cannot be guaranteed. The
manufacturer does not recommend the

use of larger diameter wire.

WELDER OPERATING

CHARACTERISTICS

DUTY CYCLE

The duty cycle rating of a welder defines

how long the operator can weld and how
long the welder must be rested and

cooled. Duty cycle is expressed as a
percentage of 10 minutes and

represents the maximum welding time
allowed. The balance of the 10-minute

cycle is required for cooling_
Your new welder has a duty cycle rating

of 20% at the rated output. This means
that you can weld for two (2) minutes out

of 10 with the remaining eight (8) minutes
required for cooling. (See Table 2).

Table 2. Duty Cycle Ratings

Duty Maximum Required
Cycle Welding Resting

Rating Time Time

20% 2 minutes 8 minutes

40% 4 minutes 6 minutes
60% 6 minutes 4 minutes
80% 8 minutes 2 minutes

100% 10 minutes 0 minutes

INTERNAL THERMAL
PROTECTION

CAUTION

Do not constantly exceed the duty
cycle or damage to this welder can

result. If you exceed the duty cycle of
your welder, an internal thermal

protector will open, shutting off all
welder functions except the cooling

fan If this happens, DO NOT SHUT
OFF THE WELDER. Leave the

welder turned on with the fan running.
After cooling, the thermal protector will

automatically reset and the welder will
function normally again. However,
you should wait at least 10 minutes

after the thermal protector opens
before resuming welding. You must

do this even if the thermal protector

resets itself before the t0 minutes is
up or you may experience tess than

specified duty cycle performance.

If you find that your welder will not weld
for 2 minutes without stopping, reduce
the wire speed slightly and tune the

welder in at the lowest wire speed

setting that still produces a smooth arc_

Welding with the wire speed set too high

causes excessive current draw and

shortens the duty cycle°